Sol-Gel Coated Reinforcement Elements for Rubber Adhesion
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Solution Overview
Problem
The challenge lies in achieving effective adhesion between elastomeric matrix materials, such as rubber, and reinforcement elements like textile fibers and metallic cords, particularly in tire manufacturing, where the differing modulus of elasticity and surface chemistry hinder strong bonding, and existing adhesion promoters like RFL dip raise health and environmental concerns.
Innovation Solution
A method involving a sol-gel coating of the reinforcement elements followed by exposure to a low-pressure plasma treatment, which enhances adhesion by creating a more effective sol-gel layer that surpasses the bonding achieved with traditional oven-drying methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional adhesion promoters like RFL dip (resorcinol/formaldehyde mixture) are used to improve adhesion between reinforcement elements and elastomeric matrix, then adhesion strength is improved, but health and environmental safety deteriorates
Solution Approach 1:
The patent removes the harmful resorcinol and formaldehyde components from the adhesion promoter composition, replacing them with a sol-gel coating system that achieves equivalent or superior adhesion without the toxic substances. This extraction of harmful elements directly resolves the contradiction between adhesion strength and health/environmental safety.
Solution Approach 2:
The invention changes the chemical composition parameters of the adhesion promoter from a resorcinol/formaldehyde/latex mixture to a sol-gel precursor composition containing silicon-based compounds and organic modifiers. This parameter change maintains the adhesion function while eliminating the harmful effects of the original chemicals.
2Strength
If sol-gel coating is applied to reinforcement elements to improve adhesion, then adhesion is improved compared to untreated elements, but the adhesion is still insufficient compared to RFL dip treatment
Solution Approach 1:
The patent applies a preliminary sol-gel coating to the reinforcement element surface before final assembly. This preliminary action modifies the surface chemistry and topology, creating a foundation for enhanced adhesion. The sol-gel layer serves as a preliminary treatment that prepares the surface for optimal bonding with the elastomeric matrix.
Solution Approach 2:
The invention creates a composite coating structure combining inorganic sol-gel components (silicon oxide network) with organic modifiers. This composite material provides both chemical bonding capability and mechanical interlocking, achieving adhesion performance that surpasses both untreated surfaces and traditional RFL dip treatment while being environmentally friendly.
3Strength
If atmospheric pressure plasma is used for surface treatment, then adhesion is improved, but fiber damage increases
Solution Approach 1:
The patent changes the plasma treatment parameters from atmospheric pressure to low pressure (vacuum conditions). This parameter change reduces the intensity and penetration depth of plasma treatment, preventing fiber damage while still achieving sufficient surface activation and adhesion improvement. The low-pressure plasma provides controlled surface modification without compromising fiber integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The low-pressure plasma treatment significantly improves the adhesion between the elastomeric matrix and reinforcement elements, outperforming untreated and RFL dip-treated samples, while avoiding the use of resorcinol and formaldehyde, and is applicable to various reinforcement materials including textile and metallic cords.
Implementation Method 1
the reinforcement element is provided with a sol-gel coating
Implementation Method 2
a sol-gel coating of the reinforcement elements followed by exposure to a low-pressure plasma treatment
Implementation Method 3
the sol-gel-coated reinforcement element is exposed to the action of a low-pressure plasma
Data Source
AI summary
The invention relates to a method for improving adhesion between a reinforcement element that comprises textile fibers or textile filaments and an elastomer matrix material, in particular uncured rubber, the reinforcement element being provided with a sol-gel coating and the sol-gel coated reinforcement element being exposed to the action of a plasma, in particular a low-pressure plasma.